Concrete form tie with connector for finishing panel

ABSTRACT

A tie for connecting and maintaining first and second panels of a concrete formwork in a fixed, spaced relationship during a wall building process is provided. The tie includes a first connector connectable to the first panel; and a second connector connectable to the second panel and connectable to at least one third panel such that the at least one third panel is spaced from the concrete surface.

FIELD OF THE INVENTION

The present invention relates to forms for concrete walls, and moreparticularly to ties for connecting and maintaining first and secondpanels of a concrete formwork in a fixed, spaced relationship during awall building process.

BACKGROUND OF THE INVENTION

Conventional formwork for forming walls from pourable building materialsuch as concrete consist of two opposed, typically plywood wallsconnected by a rod, trusswork or other connecting structure. Morerecently, it has become desirable to use insulating material such asexpandable polystyrene for the formwork, in order to provide thermal andacoustic insulation to the finished wall. In certain applications,particularly those where it is desired to inhibit the effects of“thermal inertia” of a concrete wall so as to employ the ability of theconcrete to retain heat for temperature stabilization, it is desirableto employ formwork with insulated paneling on only one side. The otherside, typically of plywood, may or may not be removed after full or atleast partial curing of die concrete.

Various insulated formworks and related technologies have beenconsidered. For example, U.S. Pat. No. 5,845,445 to Blackbeard disclosesan insulated concrete form with a plurality of plywood boards at aninside surface, and a plurality of insulating foam panels at an outsidesurface. The plywood boards and insulating foam panels are connected bya plurality of elongated vertically aligned connecting members forretaining the panels in a spaced apart parallel relationship during thewall building process. The connecting members are connected to theinsulating panels, and ties are attached to respective connectingmembers and the plywood boards. Each tie has a conventional embossed endto engage into a latch clip on the plywood side. During de-forming, theplywood boards may be removed by removing the attachment between theties and latch clips.

U.S. Pat. No. 6,314,694 to Cooper et al. discloses a one-side insulatedformwork that includes an insulating panel connectable to a removablepanel by a connecting structure, which may provide permanentreinforcement embedded in the insulating panel. The removable panel isattached to the connecting structure using removable fasteners. Theconnecting structure maintains a fixed spaced relationship between theinsulating panel and the removable panel, and according to embodimentsdisclosed includes rebar hooks for supporting rebar for embedding in theconcrete. After the concrete has at least partially cured, the removablefasteners and removable panel are removed, leaving exposed and flushwith the outer surface of the concrete wall a surface of the connectingstructure suitable for flush connection of a finishing panel.

U.S. Pat. No. 6,526,713 to Moore, Jr. discloses an insulated concretestructure for forming walls from a pourable building material such asconcrete. Moore proposed connecting two panels of a formwork using a webstructure, a portion of which is preferably embedded in an insulatingone of the panels. After the concrete has at least partially cured, oneof the panels being now adjacent to the formed wall, may be removed orremain as part of the structure.

Although the above references disclose insulated formwork of variousconfigurations, improvements are desired. For example, none of thereferences discussed above consider the challenges of installingelectrical and/or plumbing after or during the wall forming process. Itis therefore an object of the present invention to provide a novel wallform, tie and method using the same for building walls from pourablebuilding material, such as concrete.

SUMMARY OF THE INVENTION

According to an aspect, there is provided a tie for connecting andmaintaining first and second panels of a concrete formwork in a fixed,spaced relationship during a wall building process, the tie comprising:

a first connector connectable to the first panel; and

a second connector connectable to the second panel and connectable to atleast one third panel such that the at least one third panel is spacedfrom the concrete surface.

According to an embodiment, the second panel is made of plywood and thethird panel is made of drywall.

According to an embodiment, an insulating wall form comprises the tie, afirst panel made from an insulating material and connected to the firstconnector; and a second panel connected to the second connector.

According to another aspect, there is provided a method of making aconcrete wall, comprising:

providing a first panel having an inward facing surface and an outwardfacing surface, the first panel made of insulating material;

providing a second panel having an inward facing surface and an outwardfacing surface;

connecting a first connector of a tie to the first panel and a secondconnector of the tie to the second panel, wherein the first and secondconnectors are separated by an intermediate portion with a lengthcorresponding approximately to the thickness of the concrete wallthereby providing a fixed space between the first and second panels forreceiving a charge of the concrete; and

attaching a third panel to the second connector to provide a fixed spacebetween the concrete surface and the third panel.

The tie, formwork employing the same, and method for making a wallprovide previously unrealized advantages because they permit the option,of removal of the second panel after wall construction prior toattachment of the third panel, while permitting spacing between thethird panel and the concrete surface and/or second panel for passingelectrical wires and/or plumbing and the like. Thus, the electricalwires and/or plumbing may more easily be inspected and/or repaired thansystems which involve embedding such utilities in, the concrete wallitself.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments will now be described more fully with reference to theaccompanying drawings in which:

FIG. 1 is a perspective cutaway view of a formwork having first andsecond panels and a tie;

FIG. 2 is a perspective cutaway view of an at least partially setconcrete wall of FIG. 1 with a second panel having been removed and athird panel being connected;

FIG. 3 is a perspective view of an alternative tie embodiment;

FIG. 4 is a side view of a formwork having first and second panels andthe tie of FIG. 3;

FIG. 5 is a side view of the at least partially set concrete wall ofFIG. 4 with a second panel having been removed and a third panelconnected;

FIG. 6 is a perspective view of another alternative tie embodiment;

FIG. 7 is a perspective cutaway view of a formwork having first andsecond panels and an alternative tie embodiment;

FIG. 8A is a perspective view of a first connector and an intermediateportion of an alternative tie embedded in a first panel and connectableto a second panel;

FIGS. 8B and 8C are perspective views of the intermediate portion of thealternative tie of FIG. 8A embedded in an at least partially setconcrete wall and connectable to a third panel connection portion of thetie;

FIG. 8D is a perspective view of the alternative tie of FIGS. 8A-8Cbeing connected to a third panel;

FIG. 8E is a top view of alternative ties as shown in FIGS. 8A-8Dembedded in concrete and connected to a third panel;

FIG. 9 is a perspective view of another alternative tie embodiment;

FIG. 10 is a top view of the alternative tie embodiment of FIG. 9connected to first, second and third panels; and

FIG. 11 is a top partial view of an alternative tie being connected to asecond panel.

DETAILED DESCRIPTION OF THE EMBODIMENTS

In the following description, embodiments of a tie for connecting andmaintaining first and second panels of a formwork in a fixed, spacedrelationship during a wall building process, and of a method of making aconcrete wall are provided.

FIG. 1 is a perspective cutaway view of a portion of a formworkaccording to an embodiment. The formwork has at least one first panel10, at least one second panel 20 and at least one tie 50. The firstpanel 10 is an insulating panel made of polystyrene, and the secondpanel 20 is made of plywood.

The tie 50 includes a first connector 52, an intermediate portion 60,and a second connector 54. As can be seen, the first connector 52 isembedded in the first panel 10. The second connector 54 is shownconnected to the second panel 20 at a second panel connection portion 56by screws or other suitable removable fasteners. The second connector 54is removable from the second panel 20 upon removal of the fasteners. Thetie 50 maintains the first and second panels in a fixed spacedrelationship thereby to provide space between the panels for receivingand holding a charge of poured concrete 40.

The second connector 54 of the tie 50 also includes a third panelconnection portion 58 that is spaced from the second panel connectionportion 56 by virtue of the dimensions of the second connector 54 andthe relative positions of the second and third panel connection portions56, 58. More particularly, the second panel connection portion 56 andthird panel connection portion 58 are spaced apart such that the thirdpanel 30 when connected to the third panel connection portion 58 isspaced from the inside surface of the concrete wall 40. The use of thisspacing is illustrated in FIG. 2. FIG. 2 is a perspective cutaway viewof the at least partially set concrete wall 40 that was poured in FIG. 1with the second panel 20 having been removed. A third, or “finishing”panel 30 made of drywall is being connected to the third panelconnection portion 58. With the second panel 20 having been removed, thethird panel 30 connected to the third panel connection portion 58 isspaced from the inside surface of the concrete wall 40. Intermediate thesecond and third panel connection portions 56, 58 are passageways 62through second connector 54. Passageways 62 are dimensioned to permitpassage of electrical cables/wires 64 and/or plumbing (not shown) orother utilities being installed along the wall between the third panel30 and the inside surface of the concrete wall 40.

FIG. 3 is a perspective view of an alternative tie 50A. Tie 50A has aplurality of first connectors 52A and intermediate portions 60Aconnected to a second connector 54A. Second connector 54A includes asecond panel connection portion 56A connectable to one or more secondpanels 20, and a plurality of third panel connection portions 58Aconnectable to at least one third panel 30. Passageways 62 pass from oneside to the other of the second connector 54A.

FIG. 4 is a side view of a formwork having first and second panels 10,20 and the tie 50A of FIG. 3 during pouring of concrete 40.

FIG. 5 is a side view of the at least partially set concrete wall 40 ofFIG. 4 with the second panel 20 having been removed from second panelconnection portion 56A, and a third panel connected to third panelconnection portion 58A.

FIG. 6 is a perspective view of another alternative tie 50B. Tie 50B hasa single first connector 52B and intermediate portion 60B connected to asecond connector 54B. Second connector 54B includes a second panelconnection portion 56B connectable to one or more second panels 20, anda plurality of third panel connection portions 5831 connectable to atleast one third panel 30. Passageways 62 pass from one side to the otherof the second connector 54B. Open-topped channels 63 also pass from oneside to the other of the second connector 54B to ease installation ofelectrical cables/wire and/or plumbing or other utilities.

FIG. 7 is a perspective cutaway view of a formwork having first andsecond panels 10, 20 and an alternative tie 50C. Tie 50C has a singlefirst connector 52C and intermediate portion 60C. A second panelconnection portion 56C is connected to intermediate portion 60C and isremovably connected to second panel(s) 20. A third panel connectionportion 58C is removably connectable to the second panel connection,portion 56C once second panels 20 are removed after the concrete 40 hasat least partially set. Connectability between second and third panelconnection portions 56C and 58C is by virtue of the dimensions of anextension channel 57C in second panel connection portion 56C suitablefor receiving in interference fit an extension protrusion 59C of thirdpanel connection portion 58C.

Multiple ties 50C are stackable by virtue of mechanical interlockmembers. These mechanical interlock members include respective stackingprotrusions 66C on the second panel connection portion 56C and the thirdpanel connection portion 58C. The stacking protrusions 66C mate ininterference fit with respective corresponding stacking channels (notshown) in adjacent second and third panel connection portions 56C, 58Cof an adjacent tic 50C.

At the bottom of FIG. 7, a third panel 30 is shown connected to thethird panel connection portion 58C which is in turn, connected to thesecond panel connection portion 56C.

FIG. 8A is a perspective view of a first connector 52D and anintermediate portion 60D of an alternative tie 50D. First connector 52Dis embedded in a first panel 10 and is connectable to a second panel 20.For ease of transport, intermediate portion includes arms 61 which can,due to their pivotability relative to first connector 52D, fold againstthe inside surface of the first panel 10 during transportation. Arms 61can also fold towards each other and mate to form the intermediateportion 60D having a second panel connection portion 56D.

FIGS. 8B and 8C are perspective views of the intermediate portion 60D ofthe tie 50D of FIG. 8A embedded in an, at least partially set concretewall 40 and connectable to a third panel connection portion 58D of thetie 50D. Third panel connection portion 58D is connected to a thirdpanel(s) 30 after the concrete 40 has been poured and at least partiallyset and second panel(s) 20 have been removed from second panelconnection portion 56D.

FIG. 5D is a perspective view of the tie SOD of FIGS. 5A-8C beingconnected to a plurality of third panels 30, and having an electricalcable 64 passing through a passageway 62 of the third panel connectionportion 58D.

FIG. 5E is a top view of a plurality of ties 50D as shown in FIGS. 8A-8Dembedded in the concrete wall 40, and connected to third panels 30.

FIG. 9 is a perspective view of another alternative tie 50E. The tie 50Ehas an intermediate portion 60E between its first connector 52E and itssecond panel connection portion 56E, that is adjustable in length asshown in FIG. 9. Third panel connection portion 53E mates with secondpanel connection portion 56E after the concrete 40 has been poured andhas at least partially set and second panels 20 have been disconnectedfrom the second panel connection portion 56E. Third panel connectionportion 58E mates with second panel correction portion 56E by virtue ofan interference fit between an extension channel 57E in second panelconnection portion 56E and an extension protrusion 59F on third panelconnection portion 58E.

It can be seen in FIG. 9 that depending on the desired configuration offormwork, second panels 20 can occlude the extension channel 57E,requiring their removal prior to connection of the third panelconnection portion 58E. Alternatively, if it is desired to keep secondpanels 20 while connecting third panels 30, then they may be attached tothe second panel connection portion 56E so as not to occlude theextension channel 57E. In this way, the third panel connection portion58E may be connected to the second panel connection portion 56E whilesecond panels 20 remain connected to second panel connection portion56E.

FIG. 10 is a top view of the alternative tie 50E of FIG. 9 connected tofirst, second and third panels 10, 20, 30.

FIG. 11 is a top partial view of an intermediate portion 60F and asecond connector 54F of an alternative tie. Adjacent third panelconnection portion 58F of second connector 54F are flaps 55F pivotablyconnected to the second connector 54F. Flaps 55F are at least a portion,of the height of the third panel connection portion 58F (i.e. extendinto the page in FIG. 11). Other means of pivotably connecting flaps 55Fto second connector 54F may be used. Flaps 55F pivot away from secondpanels 20 in order to permit insertion of spacer boards S against secondpanels 20 and second connector 54E Once the spacer boards S are in placeas shown in FIG. 11, flaps 55F are pivoted back against the spacerboards and at least one respective fastener F is passed through flap 55Finto the respective spacer board S. The spacer board S is thereby heldagainst a respective second panel 20 and maintains the fixed formworkduring pouring of the concrete 40. Upon at least partial setting of theconcrete, the fasteners F, spacer boards S and second panels 20 may beremoved, and a Gird panel 30 then connected to the third panelconnection portion 58F of the second connector 54. It will be understoodthat an embodiment employing such flaps may be used without spacerboards where at least a part of second panel 20 is thick enough tointeract with the flaps suitably to permit second panel to be held inplace by the flaps as described.

In order to make a wall from pourable building material such asconcrete, a first panel made of an insulating material is provided. Thefirst panel has an inward facing surface facing towards the interior ofthe building, and an outward facing surface facing towards the exteriorof the building. A second panel, also having an inward facing surfaceand an outward facing surface, and preferably of plywood, is alsoprovided. The first connector of the tie is connected to the firstpanel. It will be understood that this may be done upon manufacture ofthe first panel where the insulating material is expandable polystyreneor the like such that the first connector is thereby embedded in thepanel during moulding. The second connector of the tie is then connectedto the second panel using fasteners such as screws and/or somealternative or combined mechanical connection. When the first and secondpanels are connected to the tie as described, the first and secondconnectors are separated by an intermediate portion with a lengthcorresponding approximately to the thickness of a wall being made. Afixed space between die first and second panels for receiving a chargeof the concrete is thereby provided. A charge of concrete is thenprovided into the fixed space between the first and second panels. Theelectrical cable and/or plumbing may be passed through passageways 62prior to connection of the third panel, preferably made of drywall.

It will be understood that, in some embodiments, the third panel may beconnected prior to pouring of the concrete into the fixed space betweenthe second and third panels. If electrical cable and/or plumbing arerequired, then this of course is installed prior to connection of thethird panels. In some cases, the second panels would remain part of thefinished wall, albeit hidden from view inside the building by the thirdpanels. Furthermore, the second panels may remain part of the finishedwall whether or not the third panels were connected prior to or afterpouring of the concrete. This is left to the preference of the builder,and the suitability of the second panel remaining part of the wall.Indeed, some described embodiments of ties described herein requireremoval of the second panel prior to connection of the third panel, andsome do not.

Depending particularly upon the required height of the concrete wallbeing built, first and second panels may be vertically stacked upon eachother to provide a formwork having a suitable height.

Embodiments of ties have been shown for use in construction environmentsin which a second panel is desired to be disconnected from the tie priorto connection of a third panel, and also in which the second panel mayremain while a third panel is being connected.

While embodiments have been shown hereby ties are stacked using amechanical interlock mechanism, other configurations are possible. Forexample, second connectors of two adjacent ties may cooperate with eachother to connect to second and/or third panels without interlocking. Insuch an embodiment, two second connectors of two ties may have secondpanel connection portions that do not mechanically interlock or eventouch, but align to both receive a common second panel. In other orcomplementary embodiments, the first portion of a tie may span theentire height of a first panel, while intermediate portions and/orsecond portions do not. Various combinations and modifications withinthe scope of the invention are possible.

While embodiments have been shown that have the third panel spaced fromthe second panel, it will, be understood that second panels may beprovided that are dimensioned and configured with respect to a tie sothat there is little or no space between the third and second panels. Itwill be understood that in such embodiments, the second panel isintended to be disconnected from the formwork prior to connection of athird panel, such that the third panel is in fact spaced from theconcrete wall surface thereby permitting passage of electricalcables/plumbing and the like between the third panel and the concretewall surface.

Although embodiments have been described, those of skill in the art willappreciate that variations and modifications may be made withoutdeparting from the spirit and scope thereof. As defined by the appendedclaims.

1. A tie for connecting and maintaining first and second panels of aconcrete formwork in a fixed, spaced relationship during a wail buildingprocess, the tie comprising: a first connector connectable to the firstpanel; and a second connector connectable to the second panel andconnectable to at least one third panel such that the at least one thirdpanel is spaced from the concrete surface.
 2. The tie of claim 1,wherein the second connector is removably connectable to the secondpanel.
 3. The tie of claim 1, wherein the second connector is removablyconnectable to the at least one third panel.
 4. The tie of claim 1,wherein the first connector is embeddable in the first panel.
 5. The tieof claim 4, wherein the first panel is made of insulating material. 6.The tie of claim 1, wherein the second connector comprises a secondpanel connection portion and a third panel connection portion.
 7. Thetie of claim 6, wherein the third panel connection portion is removablyconnectable to the second panel connection portion.
 8. The tie of claim6, wherein the second connector comprises at least one passagewaybetween the concrete surface and the third panel, for supporting anelectrical cable and/or plumbing.
 9. The tie of claim 8, wherein atleast one of the at least one passageway is an open-topped passageway.10. The tie of claim 1, wherein the second connector is dimensioned tocooperate with a second connector of at least one other tie.
 11. The tieof claim 10, wherein the second connector is dimensioned to be coupledwith the second connector of the at least one other tie.
 12. The tie ofclaim 11, wherein the second connector comprises a mechanical interlockmechanism for coupling with the second connector of the at least oneother tie.
 13. The tie of claim 1, comprising at least one flappivotably connected to the second connector for connecting the secondconnector to a second panel.
 14. The tie of claim 1, wherein the firstconnector and second connector are linked by an intermediate portion,the intermediate portion removably connectable to the first connector.15. The tie of claim 14, wherein the intermediate portion is removablyconnectable to the second connector.
 16. The tie of claim 1, wherein thetie is made of plastic.
 17. An insulating wall form comprising: the tieof one of claims 1 to 16; a first panel made from an insulating materialand connected to the first connector; and a second panel connected tothe second connector.
 18. The insulating wall form of claim 17, whereinthe first connector is embedded in the first panel.
 19. The insulatingwall form of claim 17, wherein the second connector is removablyconnected to the second panel.
 20. A method of making a concrete wallcomprising; providing a first panel having an inward facing surface andan outward facing surface, the first panel made of insulating material;providing a second panel having all inward facing surface and an outwardfacing surface; connecting a first connector of a tie to the first paneland a second connector of the tie to the second panel wherein the firstand second connectors are separated by an intermediate portion with alength corresponding approximately to the thickness of the concrete wallthereby providing a fixed space between the first and second panels forreceiving a charge of the concrete; and attaching a third panel to thesecond connector to provide a fixed space between the concrete surfaceand the third panel.
 21. The method of claim 20, comprising: providing acharge of concrete into the fixed space between the first and secondpanels.
 22. The method of claim 21, wherein the charge of concrete isprovided prior to attaching the third panel.
 23. The method of claim 20,wherein providing the first and second panels comprises verticallystacking multiple panels.
 24. The method of claim 20, wherein the firstpanel is moulded and connecting the first connector to the first panelis performed during moulding.
 25. The method of claim 20, wherein thesecond connector comprises at least one passageway, the method furthercomprising: prior to attaching the third panel passing electrical cablesand/or plumbing through the passageway.